Hydrodemetallization catalyst and process

ABSTRACT

This invention is directed to hydrodemetallization catalysts and hydrodemetallization processes employing a magnesium aluminosilicate clay. The magnesium aluminosilicate clay has a characteristic  29 Si NMR spectrum. The magnesium aluminosilicate clay is the product of a series of specific reaction steps. Briefly, the magnesium aluminosilicate clay employed in the catalyst and process of the invention is made by combining a silicon component, an aluminum component, and a magnesium component, under aqueous conditions and at an acidic pH, to form a first reaction mixture and subsequently the pH of the first reaction mixture is adjusted to greater than about 7.5 to form a second reaction mixture. The second reaction mixture is allowed to react under conditions sufficient to form the magnesium aluminosilicate clay. The resulting magnesium aluminosilicate clay combines high surface area and activity for use in hydrodemetallization catalysts and processes.

This application is related to two co-filed patent applications titled “Hydrocracking catalyst and process using a magnesium aluminosilicate clay” and “Magnesium aluminosilicate clays—synthesis and catalysis,” herein incorporated in their entirety.

FIELD OF THE INVENTION

This invention is directed to hydrodemetallization catalysts and hydrodemetallization processes employing a magnesium aluminosilicate clay.

BACKGROUND OF THE INVENTION

As feedstocks become heavier and contain increasing amounts of heteroatoms, new processes for upgrading these feedstocks are important. For example, improved processes for hydrodemetallization need to be developed to remove vanadium, nickel, and other metals. Heavier feedstocks also require hydrocracking and other hydroprocessing to yield more valuable products such as gasoline, diesel, jet fuel, and lube oil.

Hydrodemetallization catalysts can comprise various components. One component which can be used used in hydrodemetallization catalysts is a magnesium aluminosilicate clay. Layered magnesium aluminosilicates can be described as a type of clay comprising alternating layers of octahedrally coordinated magnesium atoms and tetrahedrally co-ordinated silicon and/or aluminum atoms. Magnesium aluminosilicate clays have a negative layer charge which can be balanced by cations. The literature contains examples of magnesium aluminosilicate clays used as catalysts or as components of catalysts.

While synthesis of clays can be difficult, particularly on a large scale, clays have received attention for use in hydroprocessing reactions. For example, U.S. Pat. No. 3,844,978 discloses a layer-type, dioctahedral, clay-like mineral that is a magnesium aluminosilicate. The clay can be used as a catalyst or as a component in a catalyst composition.

U.S. Pat. No. 3,844,979 discloses a layer-type trioctahedral, clay-like mineral that is a magnesium aluminosilicate, a catalyst composition comprising said magnesium aluminosilicate, and hydroprocesses using said magnesium aluminosilicate.

U.S. Pat. No. 3,887,454 discloses hydroconversion processes using a layer-type, dioctahedral, clay-like mineral that is a magnesium aluminosilicate. Catalyst compositions and hydroprocessing reactions using catalyst compositions comprising magnesium aluminosilicates and hydrogenation components such as Group VIII metals are also disclosed.

U.S. Pat. No. 6,187,710 and U.S. Pat. No. 6,565,643 disclose synthetic swelling clay minerals, methods of making swelling clay minerals, and the use of said swelling clay minerals as hydrocarbon reaction catalysts. U.S. Pat. No. 6,334,947 discloses catalysts compositions comprising a swelling clay and the use of said catalyst compositions in hydroprocessing reactions. Magnesium aluminosilicates are examples of swelling clays disclosed in U.S. Pat. No. 6,187,710, U.S. Pat. No. 6,565,643, and U.S. Pat. No. 6,334,947.

There exists a need for magnesium aluminosilicate clays with improved characteristics that can be used as catalysts or components of catalyst compositions in hydrodemetallization catalysts and processes.

SUMMARY OF THE INVENTION

This application discloses hydrodemetallization catalysts comprising a magnesium aluminosilicate clay wherein the magnesium aluminosilicate clay is synthesized according to a process comprising the following steps:

-   -   a) combining (1) a silicon component, (2) an aluminum component,         and (3) a magnesium component, under aqueous conditions at a         first reaction temperature and at ambient pressure, to form a         first reaction mixture, wherein the pH of said first reaction         mixture is acidic;     -   b) adding an alkali base to the first reaction mixture to form a         second reaction mixture having a pH greater than the pH of the         first reaction mixture; and     -   c) reacting the second reaction mixture at a second reaction         temperature and for a time sufficient to form a product         comprising a magnesium aluminosilicate clay.

Another aspect of the invention are hydrodemetallization catalysts comprising the magnesium aluminosilicate clay synthesized in the steps set forth above, wherein said hydrodemetallization catalysts further comprise one or more catalytically active metals. Particularly useful catalytically active metals are Group VIB and/or Group VIII metals, particularly cobalt, nickel, molybdenum, and tungsten.

This application also discloses hydrodemetallization catalyst compositions comprising a magnesium aluminosilicate clay wherein said magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3 and wherein the ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as given in Table 1.

TABLE 1 Chemical Peaks shift (ppm)¹ P1 −79 P2 −82 P3 −85 P4 −88 P5 −93 ¹+/−3 ppm

In an embodiment, the magnesium aluminosilicate clay is mesoporous.

Another aspect of the invention is a hydrodemetallization process comprising the step of contacting a hydrocarbonaceous feedstock under hydrodemetallization conditions with a catalyst comprising a magnesium aluminosilicate clay wherein said magnesium aluminosilicate clay is synthesized according to a method comprising the following steps:

-   -   a. combining (1) a silicon component, (2) an aluminum component,         and (3) a magnesium component, under aqueous conditions at a         first reaction temperature and at ambient pressure, to form a         first reaction mixture, wherein the pH of said first reaction         mixture is acidic;     -   b. adding an alkali base to the first reaction mixture to form a         second reaction mixture having a pH greater than the pH of the         first reaction mixture; and     -   c. reacting the second reaction mixture at a second reaction         temperature and for a time sufficient to form a product         comprising a magnesium aluminosilicate clay.

In another embodiment, the invention is a hydrodemetallization process comprising the step of contacting a hydrocarbonaceous feedstock under hydrodemetallization conditions with a catalyst comprising at least a magnesium aluminosilicate clay wherein the magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3 and wherein the ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as given in Table 1:

TABLE 1 Chemical Peaks shift (ppm)¹ P1 −79 P2 −82 P3 −85 P4 −88 P5 −93 ¹+/−3 ppm

Other objects and advantages will become apparent from the detailed description and the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

The hydrodemetallization catalysts of the invention comprise a magnesium aluminosilicate clay. The magnesium aluminosilicate clay is prepared by the following steps:

-   -   a) combining (1) a silicon component, (2) an aluminum component,         and (3) a magnesium component, under aqueous conditions at a         first reaction temperature and at ambient pressure, to form a         first reaction mixture, wherein the pH of said first reaction         mixture is acidic;     -   b) adding an alkali base to the first reaction mixture to form a         second reaction mixture having a pH greater than the pH of the         first reaction mixture; and     -   c) reacting the second reaction mixture at a second reaction         temperature and for a time sufficient to form a product         comprising a magnesium aluminosilicate clay.

The magnesium aluminosilicate clay can then be converted to a protonated form by exchanging the alkali cations in an ion exchange reaction. Generally, the alkali cations are exchanged for ammonium cations. The resulting ammonium substituted magnesium aluminosilicate clay is then deammoniated by calcination resulting in the protonated form of the magnesium aluminosilicate clay. Calcination of the magnesium aluminosilicate clay can occur prior to, during, or after formation of the hydrodemetallization catalyst. The magnesium aluminosilicate clay synthesized by the above described process can be composited with a number of other components to form the hydrodemetallization catalyst of the invention. Examples of other components include, but are not limited to, zeolites, inorganic oxides, active metals, molecular sieves, and other clays. Another aspect of the invention is hydrodemetallization processes employing the catalysts described above.

DEFINITIONS

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

The following terms will be used throughout the specification and will have the following meanings unless otherwise indicated.

As used herein “hydrothermal” refers to reactions performed in the presence of water or steam at temperatures above 100° C. and at pressures above atmospheric pressures (i.e. above about 1.2 bar).

As used herein “hydrocarbon” refers to any compound which comprises hydrogen and carbon, and “hydrocarbonaceous feedstock” refers to any charge stock which contains greater than about 90 weight percent carbon and hydrogen.

As used herein “Group VIB” or “Group VIB metal” refers to one or more metals, or compounds thereof, selected from Group VIB of the CAS Periodic Table.

As used herein “Group VIII” or “Group VIII metal” refers to one or more metals, or compounds thereof, selected from Group VIII of the CAS Periodic Table.

As used herein “aqueous mixture” refers to a combination of one or more components in the presence of water. The components can be soluble, somewhat soluble, or insoluble. The aqueous mixture can be homogeneous or heterogeneous.

The term “mesoporous” refers to an average pore size of about 2 to 50 nm.

The term “ambient pressure” refers to pressures in the range of about 0.9 bar to about 1.2 bar.

The BET surface area is determined by adsorption of nitrogen at 77K and mesopore surface area by the BJH method (described in E. P. Barrett, L. C. Joyner and P. H. Halenda, J. Amer. Chem. Soc., 73, 1951, 373.). The micropore volume is determined by the DR equation (as described in Dubinin, M. M. Zaverina, E. D. and Raduskevich, L. V. Zh. Fiz. Khimii, 1351-1362, 1947). The total pore volume is determined from the nitrogen adsorption data, the mesopore volume is determined by the difference between total pore volume and the micropore volume.

²⁹Si NMR spectra can be collected at a spinning speed of 8 kHz with at least 500 scans and a relaxation time of 100 seconds between scans.

Silicon to aluminum elemental mole ratios of magnesium aluminosilicate clays can be determined from the ²⁹Si NMR based on peak intensities. See, for example, G. Engelhardt and D. Michel (1987), High-Resolution Solid-State NMR of silicates and Zeolites. New York: John Wiley & Sons, in particular pages 180-187.

The synthesis process for making the magnesium aluminosilicate clay employed in the invention comprises forming an aqueous mixture of a silicon component, an aluminum component, and a magnesium component under acidic conditions to form a first reaction mixture. As used herein “component” refers to any material, salt, and/or compound comprising a given element which can act as a source of said element. For example “silicon component” can refer to silicon in the elemental form, silicon containing compounds, and/or silicon salts which can be used as a source of silicon. Examples of silicon components include, but are not limited to, sodium silicate, potassium silicate, silica gels, silica sols, and combinations thereof. In one embodiment, the silicon component is sodium silicate. Examples of aluminum components include, but are not limited to, sodium aluminate, potassium aluminate, aluminum sulfate, aluminum nitrate, and combinations thereof. In one embodiment of the invention, the aluminum source is aluminum nitrate. Examples of magnesium components include, but are not limited to, magnesium metal, magnesium hydroxide, magnesium halides, magnesium sulfate, and magnesium nitrate. In one embodiment of the invention the magnesium component is magnesium nitrate.

In the first reaction mixture, the ratio of silicon to aluminum to magnesium, can be expressed in terms of elemental mole ratios as:

-   -   aSi:bAl:cMg

wherein “a” has a value from 6 to 8, “b” has a value from 0.001 to 7.9, and “c” has a value of from 0.1 to 6, wherein b=(6-c)+(8-a), and wherein a:b is at least 3.

The silicon, aluminum, and magnesium components are combined, under aqueous conditions, to form a first reaction mixture under acidic conditions. In embodiments, the first reaction mixture has a pH of between about 0 to about 5. The pH of the first reaction mixture can be adjusted by the addition of an acid in order to achieve a pH of between about 0 to about 5. Examples of acids include, but are not limited to, mineral acids such as sulfuric acid, hydrochloric acid, and nitric acid. Organic acids such as acetic acid, citric acid, formic acid, and oxalic acid can also be used.

The first reaction mixture is generally formed under ambient pressure and temperature conditions. Pressures ranges for the reaction are between about 0.9 bar and 1.2 bar, preferably between about 1.0 bar and about 1.1 bar. The temperature for the formation of the first reaction mixture is not critical. Generally, the temperature is between the freezing point and the boiling point of the reaction mixture. The temperature can be about 0° C. and 100° C. and preferably at least 50° C.

After addition of the silicon, aluminum, and magnesium components and adjustment of the pH to between about 0 to about 5 to form the first reaction mixture, an alkali base is added to form a second reaction mixture. Examples of alkali base include, but are not limited to, sodium hydroxide and potassium hydroxide. Sufficient alkali base is added to the first reaction mixture so as to ensure that the pH of the resulting second reaction mixture is at least 7.5.

The second reaction mixture is then reacted for sufficient time and at sufficient temperature to form the magnesium aluminosilicate clay used in the catalysts and processes of the invention. In embodiments, the time is at least one second, preferably at least 15 minutes, and most preferably at least 30 minutes. In some embodiments, precipitation of the magnesium aluminosilicate clay can be instantaneous. Generally, the temperature is between the freezing point and the boiling point of the reaction mixture. The temperature can be from about 0° C. to about 100° C. In an embodiment, the temperature of the second reaction mixture is at least 50° C. Generally, higher temperatures result is shorter times to form the magnesium aluminosilicate clay. The second reaction mixture step can be done at ambient pressure, although higher or lower pressures are not excluded. In the synthesis process described, the magnesium aluminosilicate clay is formed in the second reaction mixture step. In some embodiments, the magnesium aluminosilicate clay quantitatively precipitates from the second reaction mixture. The second reaction mixture, upon precipitation of the magnesium aluminosilicate clay comprises the solid magnesium aluminosilicate clay and a supernatant. By “supernatant” it is meant the aqueous portion of the reaction mixture that is in liquid form, essentially free of solid or particulate material. The magnesium aluminosilicate clay can be collected by, for example, filtration, evaporation of the supernatant, or centrifugation. The addition of an alkali base during the second step of the synthesis process will incorporate alkali cations into the magnesium aluminosilicate clay.

The magnesium aluminosilicate clay can then be washed, and/or dried, and/or ion exchanged, and/or calcined. In embodiments, the magnesium aluminosilicate clay is subjected to an ion exchange reaction with an ammonium salt solution, wherein at least a portion of the alkali in the product is exchanged for ammonium cations. The magnesium aluminosilicate clay need not be isolated from the second reaction mixture before ion exchange. For example, an ammonium salt in solid or solution form can be directly added to the second reaction mixture after the precipitation of the magnesium aluminosilicate clay. Examples of ammonium salts include, but are not limited to, ammonium nitrate, ammonium bicarbonate, and ammonium chloride. Generally, the ammonium cations will have the formula [NH_(x)R_(y)]⁺, where R is any alkyl or other organic radical group, x=1-4, y=0-4, and x+y=4. In a preferred embodiment, the ammonium cations are NH₄ ⁺ cations. After ion exchange the magnesium aluminosilicate product can then be separated from the supernatant by filtration, centrifugation, or any other methods known in the art. The product can then be dried and/or calcined.

The supernatant from the ion exchange step can be collected for use in other applications. For example, if nitric acid was used during synthesis and the ion exchange reaction used ammonium cations, the effluent will be rich in ammonium nitrate. After isolation of the magnesium aluminosilicate clay, the ammonium nitrate rich supernatant can be used as a fertilizer or as a component in a fertilizer. Because the precipitation of the magnesium aluminosilicate product can be essentially quantitative, the supernatant can have essentially no magnesium, silicon, or aluminum present. The presence of excess amounts of silicon and/or aluminum and/or magnesium would render the supernatant less useful as a fertilizer or fertilizer component. By using the supernatant as well as the magnesium aluminosilicate clay product, an economic benefit can be realized in that there is little waste of reagents or costly recycling of magnesium, silicon, and/or aluminum containing supernatent.

Before use as a catalyst or as a component in a catalyst, the magnesium aluminosilicate clay can be calcined. The magnesium aluminosilicate clay can be combined with other components before or after calcination. Calcination is generally performed at temperatures between about 750° F. to about 1700° F. for a time ranging from about 1 hour to about 12 hours under an inert atmosphere. Calcination reaction times and temperatures are not critical. For example, if the magnesium aluminosilicate clay comprises ammonium cations, the calcination is generally performed at sufficient temperature and for sufficient time so as to deammoniate or remove other nitrogen containing compounds from the product, leaving protons as the charge compensating ions in the product. By deammoniate it is meant that ammonia is driven off, leaving protons as the charge compensating ions in the product.

The product of the above described process is a magnesium aluminosilicate clay. The ratio of silicon to aluminum in the magnesium aluminosilicate clay is at least 3. The ratio of silicon to aluminum to magnesium of the magnesium aluminosilicate clay can be expressed in terms of elemental mole ratios:

-   -   dSi:eAl:fMg

wherein “d” has a value from 6 to 8, “e” has a value from 0.001 to 7.9, and “f,” has a value of from 0.1 to 6, wherein e=(6-f)+(8-d), and wherein d:e is at least 3.

The magnesium aluminosilicate clay employed in the catalyst and process of the invention is a layered material composed of elemental clay platelets. The size of the clay platelets of the magnesium aluminosilicate clay is dependent on the reacting temperature and the reacting time of the second reaction mixture. Generally, the higher the temperature and the longer the time, the larger the clay platelets will be. Depending of the desired size of the clay platelets in the product, reacting time and temperature can be varied accordingly. In one embodiment the magnesium aluminosilicate comprises clay platelets with an average size of from about 5 nm to about 500 nm in the longest dimension. In another embodiment the product comprises clay platelets with an average size of from about 5 nm to about 50 nm in the longest dimension.

The degree of stacking of the clay platelets is dependent on the ionic strength of the second reaction mixture. A high ionic strength will give much-stacked structures, while a low ionic strength will lead to structures exhibiting little stacking. The ionic strength of the second reaction mixture can be adjusted by increasing or decreasing the concentration of reactants (silicon, aluminum, and magnesium components) and altering the pH. For example, a dilute solution with a pH about 8 will have a lower ionic strength than a solution with a high concentration of reactants and a pH higher than 8. In one embodiment, the clay platelets have a degree of stacking of between 1 to about 5, in another embodiment the clay platelets have a degree of stacking of between about 1 to about 3. The lower limit is constituted by unstacked clay platelets, which have a “degree of stacking” of 1. The two parameters—the size of the clay platelets and the degree of stacking—can be estimated by means of transmission electron microscopy (TEM) and powder x-ray diffraction respectively. In an embodiment, the powder x-ray diffraction of the magnesium aluminosilicate clay of the invention has only broad peaks. Broad peaks are indicative of a low degree of stacking.

The individual clay platelets are composed of sheets of octahedrally coordinated metal ions interlinked by means of oxygen ions and sheets of tetrahedrally coordinated metal ions interlinked by oxygen ions. The apical oxygen atoms of the tetrahedral sheets help form the base of the octahedral sheets, thus connecting the sheets to one another. A regular assemblage of sheets (for example tetrahedral-octahedral or tetrahedral-octahedral-tetrahedral) is called a layer. If the sheet arrangement is tetrahedral-octahedral it is referred to as 1:1, if the sheet arrangement is tetrahedral-octahedral-tetrahedral it is referred to as 2:1. The product of the present invention can be described as a 2:1 layered magnesium aluminosilicate.

The catalytic activity of the magnesium aluminosilicate clay stems in part from the charge on the sheets. A neutral tetrahedral sheet requires that the tetrahedrally co-ordinated metal ion have a tetravalent charge. In general, the metal ion will be Si⁴⁺. To have a neutral octahedral layer, the metal ions present in that layer will have to provide a total charge of 6+ for every three octahedral cavities. This can be achieved by filling two out of every three octahedral cavities with trivalent metal ions, such as Al³⁺, or by filling all octahedral cavities of each set of three with divalent metal ions, such as Mg²⁺. This gives two types of octahedral layers, trioctahedral layers, in which all octahedral sites are filled and dioctahedral layers, which have two thirds of the octahedral sites filled. We believe that the product of the present invention comprises a 2:1 trioctahedral magnesium aluminosilicate. For further description of clay classification see J. Theo Kloprogge, Sridhar Komarneni, and James E. Amonette, “Synthesis of smectite clay minerals; a critical review” Clays and Clay Minerals; October 1999; v. 47; no. 5; p. 529-554, herein incorporated by reference.

When lower valency cations are substituted or partially substituted for higher valency cations in the clay platelet structure, the clay platelet is negatively charged. For instance, in the tetrahedral layer trivalent metal ions, for example Al⁺³, may be substituted for a portion of the tetravalent metal ions such as Si⁺⁴. In the case of a clay with a trioctahedral layer structure, such as the product of the process of the present invention, such a substitution will give a saponite or a vermiculite. The divalent Mg²⁺ metal ions in the octahedral layer can be substituted or partially substituted by monovalent metal ions such as Na⁺, K⁺, or Li⁺.

In an embodiment of the invention, the magnesium aluminosilicate clay has at least 0.1 atomic %, as compared with the neutral clay, of the silicon, aluminum, and/or magnesium cations replaced by cations of a lower valency. Preferably, at least 1 atomic %, more preferably at least 5 atomic %, of the silicon, aluminum, and/or magnesium cations in the clay platelets is replaced by cations of a lower valency. In the octahedral layer, preferably not more than 50 atomic % of the magnesium ions is replaced by ions of a lower valency as compared with the neutral situation, more preferably not more than 30 atomic % is replaced. In the case of the tetrahedral layer, preferably not more than 30 atomic % of the silicon ions present is replaced by ions of a lower valency, more preferably not more than 15 atomic %. Isomorphous substitution may occur only in the octahedral layer, only in the tetrahedral layer, or in both layers. In this context the term isomorphous substitution also refers to the removal of cations without the incorporation into the lattice of replacement cations, by which vacancies are produced. It will be clear that this removal also generates negative charges.

The neutral tetrahedral layer comprises Si⁴⁺ ions. At least a portion of the Si⁴⁺ ions can be substituted by trivalent ions to impart a negative charge on the layer. The trivalent ions in the tetrahedral layer preferably are aluminium (Al³⁺) ions, although other trivalent ions such as chromium, cobalt (III), iron (III), manganese (III), titanium (III), gallium, vanadium, molybdenum, tungsten, indium, rhodium, and/or scandium can also be substituted. In an aspect of the invention, the magnesium aluminosilicate clay comprises at least 1 ppm Al³⁺ ions. The neutral octahedral layer comprises divalent magnesium (Mg²⁺) ions, although other divalent ions such as nickel, cobalt (II), iron (II), manganese (II), copper (II) and/or beryllium can also be incorporated into the neutral octahedral layer. The divalent ions of the neutral octahedral layer can be substituted by monovalent ions such as lithium (Li⁺) ions to impart a negative charge on the octahedral layer.

The negative charge generated by isomorphous substitution is counterbalanced by the incorporation of cations, also known as counter-ions, into the space between the clay platelets. These counter-ions often are sodium or potassium. Generally, these cations are incorporated in the hydrated form, causing the clay to swell. For this reason, clays with negatively charged clay platelets are also known as swelling clays. It is because of the negative charge caused by isomorphous substitution that clays can be advantageous for use in catalysis, since it gives them the potential to function as solid acids. However, to be able to function as solid acids, it is essential that the clay minerals comprise protons, since these are at least partially responsible for the catalytic activity of these compounds. Protons can be incorporated into the clay by replacing the non-hydrolyzable counter-ions such as sodium or potassium with ammonium ions and then heating the whole. This process will deammoniate the material, leaving a proton. Protons can also be introduced by replacing the counter-ions with hydrolyzable metal ions such as Mn(II) and Ca(II).

Generally, a hydrolysable metal ion (M^(n+)) may hydrolyze according to the following scheme, depending upon pH and concentration: M^(n+)+xOH⁻

^(M(OH)) _(x) ^((n−x)+),  (1) M(OH)_(x) ^((n−x)+)+OH⁻

M(OH)_(x+1) ^((n−x+1)+),  (2) M(OH)_(x) ^((n−x)+)+H⁺

M(OH)_(x−1) ^((n−x+1)+)+H₂O.  (3)

With equation (3) yielding a proton.

The magnesium aluminosilicate clay employed in the catalysts and processes of the invention can be characterized by surface area and pore characteristics. The magnesium aluminosilicate clay of the present invention generally has an average B.E.T. surface area in the range of 100 to 1000 m²/g and preferably in the range of 400 to 900 m²/g. The magnesium aluminosilicate clay has an average pore volume, determined by means of B.E.T. nitrogen adsorption, in the range of 0.3 to 2.0 cc/g, preferably in the range of at least 0.5 cc/g, and most preferably in the range of at least 0.9 cc/g. The magnesium aluminosilicate clay has an average pore size, determined by means of nitrogen adsorption/desorption in the mesoporous range. In embodiments, the magnesium aluminosilicate clay of the present invention is mesoporous with an average pore size of about 2 nm to about 50 nm.

In an embodiment, the magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3. The ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as given in Table 1.

While not being bound by any theory, we believe that the magnesium aluminosilicate clays prepared by the synthesis process described above exhibit a mesoporous internal structure, a high surface area, a uniformly small platelet size, and a low degree of stacking, which leads to a more efficient catalyst. This occurs by improving metals dispersion through more available external and internal surface yielding more sites for catalytic reactions to occur and limiting catalyst deactivation by coking, vanadium sulfide, and/or nickel sulfide deposition due to a high availability of surface area (both internal and external). In addition, we believe that the magnesium aluminosilicate clays described above exhibit greater substitution of Al³⁺ in the tetrahedral layer than magnesium aluminosilicate clays prepared by initial formation of a silica-alumina gel. The high degree of substitution of Al³⁺ for Si⁴⁺ results in a more active magnesium aluminosilicate clay after ion exchange and calcination due to higher acidity of the magnesium aluminosilicate clay.

Hydrodemetallization catalysts of the invention and employed in the process of the invention can be of widely varying composition, provided they contain the magnesium aluminosilicate clay described above. Hydrodemetallization catalysts of the invention can comprise components in such as metals, zeolites, other clays, molecular sieves, inorganic oxides, binders, diluents, and combinations thereof. The following examples of catalysts are not intended to limit in any way the scope of the invention.

The magnesium aluminosilicate clay employed in the hydrodemetallization catalyst and process of the invention can act as a support for at least one active metal. As used herein “active metal” refers to any metal or metal compound capable of lowering the energy of activation for a hydrogenation reaction. As used herein “hydrogenation metal” and “catalytically active metal” refers to any metal or metal compound capable of lowering the energy of activation for a hydrogenation reaction and is used interchangeably with “active metal.” Examples of hydrogenation metals include, but are not limited to, nickel, ruthenium, tungsten, molybdenum, cobalt, iron, and rhodium. Generally, catalytically active metals are chosen from Group VIB and/or Group VIII of the periodic table. Other metals such as tin, germanium, lead, or compounds thereof, can be added as promoters, particularly when the catalyst also contains nickel. The promotor can be present in an amount of 0.1 to 30 weight percent, preferably 0.2 to 15 weight percent, based on the catalyst and calculated as metal.

The magnesium aluminosilicate clay employed in the invention can be in an acidic form. When used in a hydrodemetallization catalyst, the magnesium aluminosilicate clay employed in the invention is preferably in an acidic form. By “acidic form” it is meant that the magnesium aluminosilicate clay is in a protonated or partially protonated form. This refers to the replacement of at least a portion of the non-acidic cations with protons to balance the negatively charged tetrahedral and/or negatively charged octahedral sheets. When the magnesium aluminosilicate clay employed in the invention is in an acidic form, the magnesium aluminosilicate can crack the hydrocarbon feedstock. Cracking of the hydrocarbon feedstock, particularly cracking of the asphaltenes helps allow efficient demetallization by removing trapped vanadium and/or nickel complexes from the asphaltene portion of the feedstock. Thus, the acidic character of the magnesium aluminosilicate clay can contribute to the overall catalytic activity of the catalyst composition.

An example of a hydrodemetallization catalyst comprises the magnesium aluminosilicate clay described above in combination with one or more inorganic oxides, Group VIB metals, and/or Group VIII metals.

Inorganic oxides such as silica, alumina, magnesia, titania, zirconia, and combinations thereof can be components of the hydrodemetallization catalyst. The inorganic oxide can contribute to the overall catalytic activity of the catalyst composition through contribution of acid sites or the inorganic oxide can act as a diluent or binder. The inorganic oxide can be crystalline, such as a zeolite or molecular sieve, or amorphous. The inorganic oxide can function as filler material, acting as diluent of the cracking activity of the clay platelets, for example, thus making it possible to regulate the cracking activity of the catalyst. The inorganic oxide can provide a matrix for one or more catalytically active components, without providing catalytic activity itself, but improving the attrition resistance of the catalyst composition. The amount of inorganic oxide to be added to the hydroprocessing catalysts of the invention generally depends on the desired activity of the final catalyst composition and can range from 0% to about 95%. The inorganic oxide can provide increased surface area for the catalytically active components of the catalyst composition. In one embodiment, the inorganic oxide can be a mesoporous inorganic oxide with an average pore size from about 2 to 50 nm as measured by nitrogen adsorption/desorption. Preferably the average pore size of the inorganic oxide is between about 7.5 to 12 nm.

The hydrodemetallization catalyst of the invention can further comprise a hydrogenation component which is selected from a Group VIB metal, a Group VIII metal, and combinations thereof. As will be evident to the skilled person, the word “component” in this context denotes the metallic form of the metal, its oxide form, or its sulphide form, or any intermediate, depending on the situation. The hydrogenation metals are selected from the Periodic Table's Group VIB and Group VIII metals (CAS Periodic Table). Generally, the catalyst will contain a Group VIB metal component and/or a non-noble Group VIII metal component. In an embodiment, the hydrogenation metal is molybdenum, tungsten, nickel, cobalt, or a mixture thereof. The Group VIB and/or non-noble Group VIII hydrogenation metal preferably is present in an amount of 2 to 50 wt. %, more preferably in an amount of 5 to 30 wt. %, most preferably in an amount of 5 to 25 wt. %, calculated as the metal oxide.

The magnesium aluminosilicate clay employed in the invention enables the hydrogenation metals, as described above, to be incorporated, at least in part, into the magnesium aluminosilicate platelet structure. For instance, cobalt or nickel may be present in the octahedral layer. In order to be catalytically active, these metals must be removed from the clay platelet structure during catalyst use. This can be done, for example, by means of reduction or sulphidation, for instance when the catalyst is sulphided under reducing conditions prior to use. Alternatively, the hydrogenation metals can be incorporated into the interlayer between the clay platelets through ion exchange. Regardless of the incorporation site, the magnesium aluminosilicate clay helps to disperse the catalytically active metal.

Various methods of adding active metals to catalyst compositions are known in the art. Briefly, methods of incorporating active metals include ion exchange, homogeneous deposition precipitation, redox chemistry, chemical vapor deposition, and impregnation. Preferably, impregnation is used to incorporate active metals into the catalyst composition. Impregnation involves exposing the catalyst composition to a solution of the metal or metals to be incorporated followed by evaporation of the solvent. In an embodiment, chelating agents are used during metal impregnation. “Chelating agents” or “chelates” can be described as a molecule containing one or more atoms capable of bonding to, or complexing with, a metal ion. The chelating agent acts as a ligand to the Group VIB and/or Group VIII metal ions, often through electron pair donor atoms in the chelating agent. Chelated metal ions tend to be more soluble and chelating agents can improve the dispersion of metal ions throughout the catalyst composition. Chelates can be polydentate, in that they can bond or complex to a metal ion through one or more positions. For example a bidentate ligand forms two bonds with a metal ion, whereas a hexadentate ligand forms six bonds with a metal ion. Examples of chelating agents include, but are not limited to, citrate, ethylene diamine tetraacetic acid (EDTA), ethylene glycol tetraacetic acid (EGTA), nitrilotriacetic acid (NTA), halides, nitrate, sulfate, acetate, salicylate, oxalate, and formate. Other examples of chelates include, but are not limited to, carboxylic acid such as glycolic acid, lactic acid, tartaric acid, malic acid, maleic acid, citric acid, glyceric acid, gluconic acid, methoxy-acetic acid, ethoxy-acetic acid, malonic acid, succinic acid and glyoxylic acid and organic sulfur compounds such as mercapto-acetic acid, 1-mercapto-propionic acid, 2-mercaptopropionic acid, 2,3-dimercapto-succinic acid, mercaptosuccinic acid, thio-acetic acid, thio-diglycolic acid, dithio-diglycolic acid, thio-salicylic acid, mercaptoethanol, β-thiodiglycol and thiourea. Other oxygen containing compounds in addition to carboxylic acids can also be used as chelating agents. Examples include, but are not limited to, ethylene glycol, propylene glycol, diethylene glycol, trimethyleneglycol, triethyleneglycol, ethyleneglycol monobutyl ether, diethylene glycol monomethyl ether, diethylene glycol monomethylether, diethylene glycol monopropyl ether, diethylene glycol monobutyl ether, glycerine, trimethylol ethane, and trimethyl propane. In an embodiment, nickel citrate solutions are used to impregnate the catalyst composition. Other examples of metal ion-chelate complexes which can be used to impregnate a catalyst or catalyst composition with metals or metal ions include nickel-EDTA, nickel-acetate, nickel-formate, molybdenum-citrate, nickel-NTA, and molybdenum-NTA. For a review see A. Jos van Dillen, R. J. A. M. Terörde, D. J. Lensveld, J. W. Geus, and K. P. de Jong, “Synthesis of supported catalysts by impregnantion and drying using aqueous chelated metal complexes”, Journal of Catalysis, 2003, p. 257-264, herein incorporated by reference in its entirety.

The Group VIB and/or Group VIII metals can be added to the magnesium aluminosilicate clay before or after calcination. For example, the magnesium aluminosilicate clay can be (1) dried, impregnated with active metal(s), extruded, and calcined, or (2) impregnated with active metal(s), extruded, and calcined, (3) dried, extruded, dried or calcined, impregnated with active metal(s), and calcined, or (4) dried, extruded, calcined, and impregnated with active metals. The magnesium aluminosilicate clay can be mixed with one or more components such as zeolites, crystalline inorganic oxide components, non-crystalline inorganic oxide components, catalytically inactive binders, diluents, and combinations thereof prior to or after impregnation with the GroupVIB and/or GroupVIII metals.

The order of addition of hydrodemetallization catalyst components to the final hydrodemetallization catalyst can vary. Catalysts comprising the magnesium aluminosilicate clay can be prepared in any way known in the art. For instance, the magnesium aluminosilicate clay can be extruded into particles, the particles calcined, and then the calcined particles impregnated with an impregnating solution containing salts of the hydrogenation metals to be introduced, optionally in combination with other components such as phosphoric acid, and/or complexing agents. Alternatively, the magnesium aluminosilicate can be mixed with other support materials such as amorphous alumina, silica alumina, and the like which may have their own catalytic activity, whereupon this mixture can be extruded and the resulting extrudates calcined. The calcined extrudates can then be impregnated as described above. It is also possible to add certain hydrogenation metal components to the catalyst composition prior to extrusion, more particularly, it is proposed to mix the magnesium aluminosilicate employed in the process of the invention and any other support materials with molybdenum oxide, after which the resulting mixture is extruded and calcined.

If the catalyst contains non-noble Group VIII metals and/or Group VIB metals as hydrogenation metals, it is preferably sulfided prior to use. This involves converting the metal components in the catalyst to their sulfided form. The sulfiding can be done by means of processes known to the skilled person, for example, by contacting the catalyst in the reactor at rising temperature with hydrogen and a sulfurous feed, or with a mixture of hydrogen and hydrogen sulfide. Ex situ presulfiding is also possible. Sulfurizing conditions include a temperature range of 200°-400° C. preferably 250°-300° C. and a pressure variable between atmospheric and high. The sulfurizing agent can be elemental sulfur, mercaptans, thiophene, or mixtures of hydrogen and hydrogen sulfide.

After sulfurization, the catalyst is ready to be used in either a conventional fixed bed reactor or an ebullating bed reactor.

Generally, the magnesium aluminosilicate clay employed in the invention can comprise from about 1% to about 30% of the hydrodemetallization catalyst. For example, catalysts are envisaged containing 1-30 wt. % of the magnesium aluminosilicate clay, 2-35 wt. % of a hydrogenation metal component, and the balance inorganic oxide matrix material. Suitable inorganic oxide matrix materials are, for example, alumina, silica, titania, zirconia, and combinations thereof. The inorganic oxide can be crystalline or noncrystalline or both. In one embodiment the inorganic oxide matrix material is alumina. In an embodiment, the hydrodemetallization catalyst comprises (1) 5 to 30 wt. % Group VIB metal, non-noble Group VIII metal, or combinations thereof, calculated as the oxide (2) 1 to 10 wt. % phosphorus calculated as P₂O₅, and (3) 1 to 30 wt % magnesium aluminosilicate clay, wherein the magnesium aluminosilicate clay is synthesized according to the process steps outlined above with the balance of the catalyst an inorganic oxide such as alumina.

In an embodiment, the catalyst comprises 5-20 wt. %, preferably 8-16 wt. %, of a Group VIB metal, calculated as the oxide. Generally, if less than 5 wt. % is used, the activity of the catalyst is insufficient. On the other hand, if more than 20 wt. %, is used, the catalytic performance is not improved further.

In another embodiment, the catalyst comprises 0.5-6 wt. %, preferably 1-5 wt. %, of Group VIII metal, calculated as oxide. If the amount is less than 0.5 wt. %, the activity of the catalyst will be too low. If more than 6 wt. % is present, the catalyst performance will not be improved further.

Optionally, a promoter such as a phosphorus, boron, or combinations thereof can be added as in known in the art. For example, it will be obvious to the skilled person that phosphorus can be incorporated into the catalyst in a suitable manner by contacting the catalyst during any one of its formative stages with an appropriate quantity of a phosphorus-containing compound, e.g., phosphoric acid. For instance, the catalyst can be impregnated with an impregnating solution comprising phosphorus in addition to any other components. If the catalyst according to the invention contains phosphorus, this compound is preferably present in an amount of 0.5-10 wt. %, calculated as P₂O₅, based on the weight of the catalyst composition.

The catalysts described above can be in the form of particles of many different shapes. The suitable shapes include spheres, cylinders, rings, and symmetric or asymmetric polylobes, for instance tri- and quadrulobes. The particles usually have a diameter in the range of 0.5 to 10 mm, and their length likewise is in the range of 0.5 to 10 mm.

The process of the invention can employ a wide variety of hydrocarbonaceous feedstocks. Hydrocarbonaceous feedstocks contain carbon compounds and can be from many different sources, such as virgin petroleum fractions, recycle petroleum fractions, shale oil, liquefied coal, tar sand oil, synthetic paraffins from NAO, recycled plastic feedstocks, biologically derived feestocks such as plant oils, plant waxes, animal fats, animal oils, and combinations thereof. Other feeds include synthetic feeds, such as those derived from a Fischer Tropsch process, including an oxygenate-containing Fischer Tropsch process boiling below about 371° C. (700° F.). Examples of feedstocks include, but are not limited to, petroleum distillates, solvent-deasphalted petroleum residua, shale oils coal tar distillates, and hydrocarbon feedstocks derived from plant, animal, and/or algal sources. The feedstocks can boil above 200° F. The feedstocks can contain substantial amounts of materials boiling in the range 350 to 950° F., and even substantial amounts of materials boiling in the range 400 to 900° F. Other suitable feedstocks include those heavy distillates normally defined as heavy straight-run gas oils and heavy cracked cycle oils, as well as conventional FCC feed and portions thereof. In general, the feed can be any carbon containing feedstock susceptible to hydroprocessing catalytic reactions. Depending on the type of processing the hydrocarbonaceous feed is to undergo, the feed can contain metal or be free of metals, it can also have high or low nitrogen or sulfur impurities.

The hydrocarbonaceous feedstocks which can be effectively treated by the catalyst include those which contain vanadium, nickel, arsenic, iron, or combinations thereof. The vanadium, nickel, arsenic, and/or iron contents of the feedstocks can exceed 1000 ppm. The feedstocks can comprise asphaltenes in amounts greater than 5 wt. %. The feedstocks can comprise asphaltenes in amounts greater than 8 wt. %. In some embodiments, the feedstocks can comprise asphaltenes in amounts greater than 25 wt.%. In embodiments, the feedstock comprises a vanadium content of greater than 10 ppm vanadium. In another embodiment the feedstock comprises a vanadium content of greater than 100 ppm vanadium. The sulfur content of the feedstocks to be processed can vary. Sulfur contents of 1%, 2% or greater are possible. Sulfur content of the feedstocks can be lower than 1%. Nitrogen content of the feedstocks can range from 0 ppm to greater than 1000 ppm.

Cracked stocks can be obtained from thermal or catalytic cracking of various stocks, including those obtained from petroleum, gilsonite, shale and coal tar. The feedstocks can be subjected to a hydrofining treatment, a hydrogenation treatment, a hydrocracking treatment, or combinations thereof, prior to contact with the catalyst of the invention. Organic nitrogen content of the feedstock is generally less than 1000 parts per million (ppm), preferably 0.5 to 500 parts per million, and more preferably, 0.5 to 100 parts per million. When contacting the catalyst of this invention, it is preferable to maintain the organic sulfur content of the feedstock in a range of from about 0 to 3 weight percent, preferably from 0 to 1 weight percent.

The hydrodemetallization of hydrocarbonaceous feeds can take place in any convenient mode, for example, in fluidized bed, moving bed, or fixed bed reactors depending on the types of process desired. The formulation of the catalyst particles will vary depending on the process and method of operation.

In an embodiment, the present invention is directed to a hydrodemetallization process comprising contacting a hydrocarbon feedstock under hydrodemetallization conditions with a catalyst comprising a magnesium aluminosilicate clay wherein said magnesium aluminosilicate clay is synthesized by a process comprising the following steps:

-   -   a) combining (1) a silicon component, (2) an aluminum component,         and (3) a magnesium component, under aqueous conditions at a         first reaction temperature and at ambient pressure, to form a         first reaction mixture, wherein the pH of said first reaction         mixture is acidic;     -   b) adding an alkali base to the first reaction mixture to form a         second reaction mixture having a pH greater than the pH of the         first reaction mixture; and     -   c) reacting the second reaction mixture at a second reaction         temperature and for a time sufficient to form a product         comprising a magnesium aluminosilicate clay.

In an embodiment, the invention is directed to hydrodemetallization processes comprising the step of contacting a hydrocarbonaceous feedstock with a catalyst composition comprising a magnesium aluminosilicate clay wherein the magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3 and wherein the ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as given in Table 1.

In another aspect, the invention is directed to a hydrodemetallization catalyst comprising a magnesium aluminosilicate clay wherein the magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3 and wherein the ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as given in Table 1:

Any suitable reaction time (contact time) between the hydrodemetallization catalyst, hydrogen and the hydrocarbonaceous feedstock can be utilized. In general, the contact time will range from about 0.1 hours to about 10 hours. Preferably, the reaction time will range from about 0.4 to about 4 hours. Thus the flow rate of the hydrocarbon-containing feed stream in a continuous operation should be such that the time required for the passage of the mixture through the reactor (residence time) will be in the range of from about 0.1 to about 10 hours, and preferably be in the range of from about 0.4 to about 4 hours. This generally requires a liquid hourly space velocity (LHSV) in the range of about 0.10 to about 10 cc of oil feed per cc of catalyst per hour, preferably from about 0.2 to about 2.5 cc/cc/hr.

According to one embodiment, the hydrocarbon feed is placed in contact with the hydrodemetallization catalyst in the presence of hydrogen, usually in a fixed bed reactor. The conditions of the hydrodemetallization process may vary according to the nature of the feed, the intended quality of the products, and the particular facilities of each refinery. The temperature is usually greater than 450° F., and is often between 600° F. and 900° F. Pressure is usually greater than 0.5 bar and often greater than 10 bar. The H₂/hydrocarbon ratio is usually greater than 100 and usually between 150 and 15,000 scfb. Liquid hourly space velocity (LHSV) is generally between 0.01 and 20 feed volumes per catalyst volume per hour. The hydrodemetallization process according to this particular embodiment is preferably performed at temperatures from 600° F. to 750° F.

Other hydroprocessing catalysts and reactions are also envisaged employing the magnesium aluminosilicate described above. Hydrocracking in combination with hydrodemetallization is a hydroprocessing reaction envisaged for catalysts comprising the magnesium aluminosilicate described herein. Table 2 gives general process conditions for catalysts comprising the magnesium aluminosilicate described above.

TABLE 2 Process Temp., ° C. Pressure LHSV Hydrocracking 175-485 0.5-350 bar 0.1-30 Dewaxing 200-475 15-3000 psig, 0.1-20 (250-450) (200-3000 psig) (0.2-10) Aromatics 400-600 atm.-10 bar 0.1-15 formation (480-550) Cat. Cracking 127-885 subatm.-¹ 0.5-50 (atm.-5 atm.) Oligomerization  232-649² 0.1-50 atm.^(2,3)  0.2-50²   10-232⁴ — 0.05-20⁵    (27-204)⁴ —  (0.1-10)⁵ Isomerization  93-538 50-1000 psig,   1-10 (204-315)  (1-4) ¹Several hundred atmospheres ²Gas phase reaction ³Hydrocarbon partial pressure ⁴Liquid phase reaction ⁵WHSV

Other hydrotreating catalysts and reactions are also envisaged employing the magnesium aluminosilicate described above. During hydrotreatment, oxygen, sulfur and nitrogen present in the hydrocarbonaceous feed is reduced to low levels. Aromatics and olefins, if present in the feed, may also have their double bonds saturated. In some cases, the hydrotreating catalyst and hydrotreating conditions are selected to minimize cracking reactions, which can reduce the yield of the most desulfided product (typically useful as a fuel).

Hydrotreating conditions typically include a reaction temperature between 400-900° F. (204-482° C.), for example 650-850° F. (343-454° C.); a pressure between 500 and 5000 psig (3.5-34.6 Mpa), for example 1000 to 3000 psig (7.0-20.8 MPa); a feed rate (LHSV) of 0.5 hr⁻¹ to 20 hr⁻¹ (v/v); and overall hydrogen consumption 300 to 2000 scf per barrel of liquid hydrocarbon feed (53.4-356 m³ H₂/m³ feed). Hydrotreating catalysts can comprise the magnesium aluminosilicate described above.

While not being bound by any theory, we believe that catalyst compositions comprising the magnesium aluminosilicate clay as described above are particularly suited for hydroprocessing reactions such as the hydrodemetallization of hydrocarbon feedstocks comprising vanadium, nickel, or combinations thereof as well as asphaltenes. Efficient hydrodemetallization occurs because of the large surface area, pore structure, and high density of acid sites of the magnesium aluminosilicate clays employed in the invention. Relatively large size organic molecules, such as high molecular weight hydrocarbons (hydrocarbons having greater than 20 carbon atoms), aromatic compounds, and asphaltenes can penetrate the mesopores of the magnesium aluminosilicate clays employed in the invention or react with acid sites on the surface of the magnesium aluminosilicate clays. The magnesium aluminosilicate clay employed in the invention, with its extensive surface area, helps disperse active Group VIB and/or Group VIII metals, providing more discreet sites for hydrogenation reactions to occur. Furthermore, the magnesium aluminosilicate clay comprising the catalysts of the invention and employed in the process of the invention exhibit higher activity than magnesium aluminosilicate clays synthesized by other methods, likely due to increased incorporation of Al³⁺ into the tetrahedral sheets, leading to higher acid site density and a more active catalyst composition. Catalyst inactivation due to deposition of vanadium sulfide and/or nickel sulfide is mitigated by the extensive available surface area of the hydrodemetallization catalysts of the invention.

EXAMPLES Example 1

A magnesium aluminosilicate clay with an elemental composition Mg5.4[Si 6.6 Al 1.4] O 20 (OH)4 with a Si/Al=4.7 was prepared as follows. Water glass (27 wt. % SiO₂) was mixed with aluminum nitrate at room temperature and the pH adjusted to about 1 with nitric acid. A solution of magnesium nitrate was added to form a first reaction mixture. The pH of the first reaction mixture was acidic. The pH of the first reaction mixture was then adjusted to about 8.4 with the addition of NaOH to form a second reaction mixture. The reaction was allowed to proceed for 1 hour at 50° C. after which time the second reaction mixture was filtered and washed, yielding a magnesium aluminosilicate clay.

Example 2

The magnesium aluminosilicate clay of Example 1 was added to a 0.1 M solution of ammonium nitrate to exchange the sodium cations for ammonium cations. The ammonium substituted magnesium aluminosilicate clay was collected by filtration and washed with water. The ammonium substituted magnesium aluminosilicate clay was then calcined at 450° C. degrees for 12 hours to convert the magnesium aluminosilicate clay to the protonated form.

Example 3

The magnesium aluminosilicate of Example 2, (16 wt. %) was mixed with alumina (84 wt. %) under aqueous conditions in the presence of nitric acid to form an extrudable mixture. The mixture was extruded, dried at 250° F. for 2 hours and then at 400° F. for 2 hours. After drying the mixture was calcined at 1200° F. for one hour to form a calcined extrudate. The calcined extrudate was then impregnated using spray impregnation with molybdenum (11 wt. %), nickel (2.7 wt. %) and phosphorus (3.85 wt %), with the metals content and phosphorus content calculated as oxides. The material was then calcined at 950° F. for 1 hour to form the hydrodemetallization catalyst of the invention.

Example 4

The magnesium aluminosilicate of Example 2, (8 wt. %) was mixed with alumina (92 wt. %) under aqueous conditions in the presence of nitric acid to form an extrudable mixture. The mixture was extruded, dried at 250° F. for 2 hours and then at 400° F. for 2 hours. After drying the mixture was calcined at 1200° F. for one hour to form a calcined extrudate. The calcined extrudate was then impregnated using spray impregnation with molybdenum (11 wt. %), nickel (2.7 wt. %) and phosphorus (3.85 wt %), with the metals content and phosphorus content calculated as oxides. The material was then calcined at 950° F. for 1 hour to form the hydrodemetallization catalyst of the invention.

Example 5 Comparative

Alumina (80.7%) was impregnated with molybdenum (12.2 wt. %), nickel (2.9 wt. %) and phosphorus (4.2 wt %), with the metals content and phosphorus content calculated as oxides. The material was calcined at 950° F. for 1 hour.

Example 6

The catalysts of Example 3 (invention), Example 4 (invention), and Example 5 (comparative) were compared for hydrodemetallization activity on a feedstock with the characteristics given in Table 3.

TABLE 3 Feedstock Nitrogen (ppm) 1878 Sulfur (wt. %) 1.92 asphaltenes 1.03 (wt. %) vis 100° C. 24.2 API 17.6 Metals ppm Ni 7 V 12.8 Fe <2

Hydrodemetallization results are given in Table 4 for the feedstock described in Table 3. Reaction conditions included a pressure of approximately 2250 psig, a molar ratio of hydrogen to hydrocarbon of 5000 scfb, and a feed rate of 0.50 hr⁻¹ LHSV. All catalysts were sulfided prior to use with a solution of DMDS (6% dimethyldisulfide in heptane).

TABLE 4 Example 3 Example 4 Example 5 (16% clay) (8% clay) (comparative) Vanadium (% 91 92 71.5 conversion) Temperature (F.) 650 646 692 Nickel (% conversion) 81 82 67 Temperature (F.) 655 655 683

Table 4 demonstrates that the hydrodemetallization catalyst of the invention has improved vanadium and nickel conversion as compared to a conventional hydrodemetallization catalyst. 

The invention claimed is:
 1. A hydrodemetallization catalyst comprising a magnesium aluminosilicate clay wherein said magnesium aluminosilicate clay is synthesized according to a method comprising the following steps wherein three separate components are used to form the clay product: a. combining three distinct components (1) a silicon component, (2) an aluminum component, and (3) a magnesium component, under aqueous conditions at a first reaction temperature and at ambient pressure, to form a first reaction mixture, wherein the pH of said first reaction mixture is acidic, the pH in the range of from 0 to 5; b. adding an alkali base to the first reaction mixture to form a second reaction mixture having a pH greater than the pH of the first reaction mixture, the ph at least 7.5; and c. reacting the second reaction mixture at a second reaction temperature and for a time sufficient to form a product comprising a magnesium aluminosilicate clay; and with the clay comprising clay platelets composed of sheets of octahedrally coordinated metal ions interlinked by means of oxygen ions and sheets of tetrahedrally coordinated metal ions interlinked by oxygen ions.
 2. The hydrodemetallization catalyst of claim 1, wherein the magnesium aluminosilicate clay comprises from about 1 wt. % to about 30 wt. % of the hydrodemetallization catalyst.
 3. The hydrodemetallization catalyst of 2, wherein the magnesium aluminosilicate clay comprises from about 5 wt. % to about 20 wt. % of the hydrodemetallization catalyst.
 4. The hydrodemetallization catalyst of claim 1, wherein the magnesium aluminosilicate clay is in the protonated form.
 5. The hydrodemetallization catalyst of claim 1, wherein the magnesium aluminosilicate clay is calcined.
 6. The hydrodemetallization catalyst of claim 1, further comprising an inorganic oxide.
 7. The hydrodemetallization catalyst of claim 6, wherein the inorganic oxide is selected from the group consisting of silica, alumina, magnesia, titania, zirconia, and combinations thereof.
 8. The hydrodemetallization catalyst of claim 1, further comprising a Group VIB metal, a Group VIII metal, or combinations thereof.
 9. The hydrodemetallization catalyst of claim 8, wherein the hydrodemetallization catalyst is sulfided.
 10. The hydrodemetallization catalyst of claim 8, wherein the Group VIB metal is chromium, molybdenum, tungsten, or combinations thereof.
 11. The hydrodemetallization catalyst of claim 8, wherein the Group VIII metal is nickel, cobalt, iron, ruthenium, rhodium, iridium, or combinations thereof.
 12. The hydrodemetallization catalyst of claim 1, further comprising from 0.5 wt. % to 10 wt. % phosphorus, calculated as P₂O₅.
 13. A hydrodemetallization catalyst comprising a magnesium aluminosilicate clay wherein the magnesium aluminosilicate clay has a silicon to aluminum elemental mole ratio greater than 3 and wherein the ²⁹Si NMR of the magnesium aluminosilicate clay comprises peaks as indicated in Table 1 below: Chemical Peaks shift (ppm)¹ P1 −79 P2 −82 P3 −85 P4 −88 P5 −93 +/−3 ppm.


14. The hydrodemetallization catalyst of claim 13, wherein the magnesium aluminosilicate clay is mesoporous. 